A manufacturing method of a textured and coated electrode wire, comprising: selecting a copper-zinc alloy as a core material, preparing, by means of electroplating/hot-dipping, a metal zinc coating on a surface of the wire material, then performing pre-treatment on the coated electrode wire by means of discontinuous diffusion annealing to obtain a coated electrode wire material having a multi-layer structure of Zn/β-Cu γ-Cu/α-Cu, and then using multiple cold drawing treatments and a stress-relief annealing treatment to modify the electrode wire and obtain a textured and coated electrode wire material. Compared to conventional copper alloy electrode wires and zinc-coated electrode wires, the material has advantages of a fast cutting speed, low cutting cost, low environmental pollution, etc., wherein the cutting speed increases by 12% or more when compared with copper alloy electrode wire, the wire breakage rate during cutting processes decreases by 30%, and the replacement time interval of an ion-exchange resin filter for cooling water increases by 10%.

A scale-style micro-texture electrode wire material and a preparation method therefor and use thereof. In particular, the electrode wire material has a scale-style micro-texture layer on the surface, and the electrode wire material comprises: i) an alloy substrate layer as an inner layer; ii) an interdiffusion layer as an intermediate layer; and iii) a plating layer as an outer layer; and a contact angle of the electrode wire material to a cooling liquid is 105-150. A method for preparing the electrode wire material and a use thereof. Due to the special surface bionic structure, the electrode wire can obviously reduce the cutting resistance and improve the cooling speed, thereby improving the cutting speed and effectively improving the use performance of the electrode wire. The preparation method has the characteristics of simple process and easy for industrial production.

A scale-style micro-texture electrode wire material and a preparation method therefor and use thereof. In particular, the electrode wire material has a scale-style micro-texture layer on the surface, and the electrode wire material comprises: i) an alloy substrate layer as an inner layer; ii) an interdiffusion layer as an intermediate layer; and iii) a plating layer as an outer layer; and a contact angle of the electrode wire material to a cooling liquid is 105-150. A method for preparing the electrode wire material and a use thereof. Due to the special surface bionic structure, the electrode wire can obviously reduce the cutting resistance and improve the cooling speed, thereby improving the cutting speed and effectively improving the use performance of the electrode wire. The preparation method has the characteristics of simple process and easy for industrial production.

Methods of repairing a part having a firtree-shaped feature requiring rework are disclosed. An embodiment of the method includes receiving the part having the firtree-shaped feature requiring rework. The part is installed in a machine configured for wire electrical discharge machining (EDM). A location of the firtree-shaped feature relative to a datum of the machine is then determined. Wire EDM is performed on the firtree-shaped feature.

Methods of repairing a part having a firtree-shaped feature requiring rework are disclosed. An embodiment of the method includes receiving the part having the firtree-shaped feature requiring rework. The part is installed in a machine configured for wire electrical discharge machining (EDM). A location of the firtree-shaped feature relative to a datum of the machine is then determined. Wire EDM is performed on the firtree-shaped feature.

Provided is a prediction device, to which one or more wire electrical discharge machines are connected, the one or more wire electrical discharge machines each performing machining on an object to be machined according to a predetermined machining condition while moving a wire electrode relatively with respect to the object to be machined along a machining path, the prediction device including a prediction unit that predicts, for a predetermined component constituting the wire electrical discharge machine, a predicted rate of consumption indicative of a rate of consumption based on the machining condition when the wire electrode is moved relatively by a unit distance, and a display unit that displays the predicted rate of consumption of the component.

Provided is a prediction device, to which one or more wire electrical discharge machines are connected, the one or more wire electrical discharge machines each performing machining on an object to be machined according to a predetermined machining condition while moving a wire electrode relatively with respect to the object to be machined along a machining path, the prediction device including a prediction unit that predicts, for a predetermined component constituting the wire electrical discharge machine, a predicted rate of consumption indicative of a rate of consumption based on the machining condition when the wire electrode is moved relatively by a unit distance, and a display unit that displays the predicted rate of consumption of the component.

Methods and systems for wire-electro discharge machining of components are described. The method comprises machining a first component by moving a wire-EDM electrode along a first set of cutting paths associated with a plurality of cutting passes, the cutting paths determined based on a desired profile shape of the component, obtaining a cutting parameter of the first component post-machining, determining a first modified cutting path for a second component based on the cutting parameter, and machining the second component by moving the wire-EDM electrode along a second set of cutting paths associated with the plurality of cutting passes, the second set of cutting paths comprising the first modified cutting path.

Methods and systems for wire-electro discharge machining of components are described. The method comprises machining a first component by moving a wire-EDM electrode along a first set of cutting paths associated with a plurality of cutting passes, the cutting paths determined based on a desired profile shape of the component, obtaining a cutting parameter of the first component post-machining, determining a first modified cutting path for a second component based on the cutting parameter, and machining the second component by moving the wire-EDM electrode along a second set of cutting paths associated with the plurality of cutting passes, the second set of cutting paths comprising the first modified cutting path.

A wire electrical discharge machine machines a workpiece so as to have different machined shapes on a top surface and a bottom surface of the workpiece. The wire electrical discharge machine includes: a distance measuring sensor for moving within a machining area of the wire electrical discharge machine and measuring a distance between the distance measuring sensor and an object to be measured; and a vertical position calculating unit for calculating a distance between a reference surface and the top surface and a distance between the reference surface and the bottom surface, from a distance between the reference surface and the distance measuring sensor, a distance between the top surface and the distance measuring sensor, and a distance between the bottom surface and the distance measuring sensor, measured by the distance measuring sensor.